Coated reinforced composite facer and insulation assembly including the same

Abstract

A coated reinforced composite facer. an insulation assembly, and a method of making a coated reinforced composite facer are provided. The coated reinforced composite facer includes a carrier substrate, a scrim, a thermoplastic coating, and a mineral coating. The thermoplastic coating adheres the scrim to one surface of the carrier substrate and the mineral coating is adhered to an opposite surface of the carrier substrate. An insulation assembly including a coated reinforced composite facer has a pull-through strength that allows the insulation assembly to be installed using fewer fasteners, while also rendering the insulation assembly relatively impermeable.

1 . A coated reinforced composite facer comprising:
 a) a carrier substrate having a first carrier surface and a second carrier surface;   b) a scrim;   c) a thermoplastic coating positioned between the scrim and the first carrier surface, wherein the thermoplastic coating adheres the scrim to the first carrier surface; and   d) a mineral coating adhered to the second carrier surface.   
     
     
         2 . The coated reinforced composite facer according to  claim 1 , wherein a total basis weight of the coated reinforced composite facer is from 185 g/m 2  to 810 g/m 2 . 
     
     
         3 . The coated reinforced composite facer according to  claim 1 , wherein the carrier substrate comprises at least one of a glass mat, a coated glass mat, an impregnated glass mat, a paper, or a metal foil, and
 wherein the carrier substrate has a basis weight of 25 g/m 2  to 150 g/m 2 .   
     
     
         4 . The coated reinforced composite facer according to  claim 1 , wherein the scrim comprises at least one of a fiberglass or a polymer,
 wherein the scrim is a laid scrim or a woven scrim, and   wherein the scrim has a basis weight of 50 g/m 2  to 200 g/m 2 .   
     
     
         5 . The coated reinforced composite facer according to  claim 1 , wherein the thermoplastic coating comprises at least one of a polyolefin, a polyacrylate, a polyester, a polyamide, a polyimide, a polycarbonate, a polyurethane, a fluoropolymer, a copolymer of an olefin and an α,β-unsaturated carbonyl, a synthetic rubber, or a thermoplastic elastomer, and
 wherein the thermoplastic coating has a basis weight of 10 g/m 2  to 60 g/m 2 . 
 
     
     
         6 . The coated reinforced composite facer according to  claim 5 , wherein the thermoplastic coating further comprises an additive comprising at least one of a fire retardant, a dye, a pigment, a UV stabilizer, an anti-static agent, or a filler. 
     
     
         7 . The coated reinforced composite facer according to  claim 1 , wherein the mineral coating comprises an inorganic filler material and a binder, and
 wherein the mineral coating has a basis weight of 100 g/m 2  to 400 g/m 2 .   
     
     
         8 . The coated reinforced composite facer according to  claim 1 , wherein the coated reinforced composite facer has an average Gurley porosity of at least 2,000 seconds. 
     
     
         9 . The coated reinforced composite facer according to  claim 1 , wherein a pull-through strength of the coated reinforced composite facer is from 350 lbf to 600 lbf when the scrim of the coated reinforced composite facer is interfaced with a polyisocyanurate foam substrate. 
     
     
         10 . An insulation assembly comprising:
 a) an insulation substrate having a first insulation surface and a second insulation surface; and   b) a coated reinforced composite facer, wherein the coated reinforced composite facer comprises:
 i) a carrier substrate having a first carrier surface and a second carrier surface; 
 ii) a scrim; 
 iii) a thermoplastic coating positioned between the scrim and the first carrier surface, wherein the thermoplastic coating adheres the scrim to the first carrier surface; and 
 iv) a mineral coating adhered to the second carrier surface, 
   wherein the scrim is attached to the first insulation surface or the second insulation surface.   
     
     
         11 . The insulation assembly according to  claim 10 , wherein the insulation substrate comprises at least one of a polyisocyanurate foam, a polyurethane foam, a polystyrene foam, or a mineral wool, and
 wherein the insulation substrate has a thickness of 0.5 cm to 12.7 cm.   
     
     
         12 . The insulation assembly according to  claim 10 , wherein a total basis weight of the coated reinforced composite facer is from 185 g/m 2  to 810 g/m 2 . 
     
     
         13 . The insulation assembly according to  claim 10 , wherein the carrier substrate comprises at least one of a glass mat, a coated glass mat, an impregnated glass mat, a paper, or a metal foil, and
 wherein the carrier substrate has a basis weight of 25 g/m 2  to 150 g/m 2 .   
     
     
         14 . The insulation assembly according to  claim 10 , wherein the scrim comprises at least one of a fiberglass or a polymer,
 wherein the scrim is a laid scrim or a woven scrim, and   wherein the scrim has a basis weight of 50 g/m 2  to 200 g/m 2 .   
     
     
         15 . The insulation assembly according to  claim 10 , wherein the thermoplastic coating comprises at least one of a polyolefin, a polyacrylate, a polyester, a polyamide, a polyimide, a polycarbonate, a polyurethane, a fluoropolymer, a copolymer of an olefin and an α,β-unsaturated carbonyl, a synthetic rubber, or a thermoplastic elastomer, and
 wherein the thermoplastic coating has a basis weight of 10 g/m 2  to 60 g/m 2 . 
 
     
     
         16 . The insulation assembly according to  claim 15 , wherein the thermoplastic coating further comprises an additive comprising at least one of a fire retardant, a dye, a pigment, a UV stabilizer, an anti-static agent, or a filler. 
     
     
         17 . The insulation assembly according to  claim 10 , wherein the mineral coating comprises an inorganic filler material and a binder, and
 wherein the mineral coating has a basis weight of 100 g/m 2  to 400 g/m 2 .   
     
     
         18 . The insulation assembly according to  claim 10 , wherein the coated reinforced composite facer has an average Gurley porosity of at least 2,000 seconds. 
     
     
         19 . The insulation assembly according to  claim 10 , wherein a pull-through strength of the insulation assembly is from 350 lbf to 600 lbf. 
     
     
         20 . A method of making a coated reinforced composite facer, the method comprising:
 a) directing a carrier substrate having a first carrier surface and a second carrier surface, a scrim, and a molten thermoplastic coating into a laminating device such that the molten thermoplastic coating is positioned between the scrim and the first carrier surface;   b) laminating together the scrim, the molten thermoplastic, and the carrier substrate; and   c) applying a mineral coating onto the second carrier surface, thereby forming the coated reinforced composite facer.   
     
     
         21 - 31 . (canceled)